Oxychloride cementatory material



?atentec1 Feb. 15, 1949 UN I TE 1) s mi es earear :orr'ics 2,4622030 I oXYcnhoRInEoiiMEN'rAromr MATERIAL Edward D. F. Whitehead, OheVyChase, Md, assignor to Whitehead-Craft Corporation, iwashington, D. C., a corporationof Delaware NoDrawin'g. Applicatioiiotober 20,1947,

SeriabNo. 781,019

1-2'Claims. 1

This invention relates to so-called Sorel type cement which is composed essentially of anaggregate combined with a magnesium oxy-chloride cementitious binder.

The use of Sore] type cement-has hei etotore been limited to applications where it is not-exposed tomoisture or water-because suchexposure, overa prolonged period, results ina deterioration of the cement. Inasmuch as magnesium .oXy-

chloride cement contains soluble ingredients, once water is absorbed into the pores of the hardened cement, the soluble ingredients are dissolved-and the cemented material rapidly deteriorates.

It is the major object of thisinvention toprovide a magnesium oxy-chloride cement which is substantially impervious and Water insoluble.

Particularly, an object of the invention is to produce a hard 'mass of mineral aggregate material surrounding, coatingand adhering to the particles of the aggregate and'fillin'g the interstices between such particles thereby forming a hardened cement which has -a substantially'impervious surface and is insoluble in Water.

More specifically, an object of the present invention is to add-chemical reagentstomagnesium oxy-chloride cement which will result in a chemical reaction producingexothermic 'heatto drive oif gases from the plastic mass, the reaction products hardening to form amineral aggregate insoluble in and practically impervious to water, the reaction. products drying into a hardened substantially impervious and water insolubl mineral aggregate.

Fundamentally, this invention is based upon the discovery that the addition of alumina and copper sulphate, copper carbonate, or a mixture-of copper sulphate and copper carbonate to a- 'cementitious mixture of silica and magnesium oxychloride causes a chemical reaction resulting in a molecular interchange between the reactive chemicals. This results in the creation of a. hard substantially impervious and insoluble material with the interstices of the mass filled by the combined magnesium, aluminum and copper compounds.

To produce this result a dry mixture is first prepared by thoroughly mixing dry finely divided silica (sand), magnesium oxide, alumina, and

copper sulphate or copper carbonate.

To the dry mixture is added a gauging solution of-magnesium chloride. This gauging solution may be prepared in many different ways but it has been found particularly advantageous to first add sufficient magnesium sulphate to a quantity'of 'waterto'neutralize the calcium content gregate may be added to the dry mixture.

of the water. After the magnesium sulphate is dissolved, sufiic'ient magnesium chloride lis-dissolved'in the'inagnes'ium sulphatesolution toproduce specific gravity of 1.21 to 1 24. For water obtained ir'o'r'n'the city supply, one liter requires approximately 13.5 grams of magnesium sulphate. To'this one liter of magnesium sulphate solution is added approximately 92-5 gramsof magnesium chloride'to'produce a solution having a specific gravity of 1.21 to 1.24. Themagnesium chloride solution is then allowed'to stand for a period of not less than 24 "hours. During this time impurities precipitated in the solution si'n'k'to the bottom so the pure solution may Ice-drained oil. The pure solution can lie-kept indefinitely withoutdeterio'rationif sealed from exposure to the air.

- This 'gauging solution is then'added to-the dry mixture and the mass 'is thoroughly [mixed to form a cementatory-material. The rplastic m-ass may be cast, poured, molded, troweled, extruded, or-pressed into a wide varietyof products.

When exposed to air'the shaped plastic mass dries into a hard stone-like mineral aggregate, having a substantially impervious surface. The material is not'only water r'epellent but isipractically insoluble in water and resists the action of many active chemicals.

Th Water repellent characteristics resulting from this invention are so improved that the hardened mineral aggregate may be used in applications where previous cementsfof the Sorel type would not be satisfactory. For example, cementatory material embodying thepresent invention maybe used to pour monolithichouses or to be coated on the'interior surfaces of water mainsto form a'l'onglasting lining. Previously known oxy-chloride cements would break down under similar exposure to moisture and Water.

Depending upon the desired end use of the bementatory material, any quantity of an inert agexample, the cementatory binder with the addition of differentqua'ntities of inert aggregate may be used tornanufacture wallboard, soundprooftil the proper consistency is attained, dependent upon the type of pro-duct and manner of application'oi the cement.

While the proportions of the ingredients may For 3 be varied within certain limits, one example of a mixture which dries without undue delay into a particularly desirable hardened mineral aggregate is as follows:

Ingredients: Mole per cent Silica SiO 35.1 Magnesium oxide MgO 20.4 Alumina A1203 2.7 Copper sulphate CUSO4.5H2O 1.0 Magnesium chloride MgClz.6HzO 3.1 Water H2O 37.7

For different purposes, the quantity of silica (sand) may be increased or decreased without affecting the water repellent characteristics of the hardened aggregate. Depending upon the quantity of silica used, the proportions of the various ingredients may be varied within the following range.

Ingredients: Mole per cent S102 26.0-58.2 MgO 23.3-13.0 A1203 3.0- 1.7 CuSO4.5H2O 1.2- 0.7 MgCl2.6H2O 3.6- 2.0 H20 43.5-24.4

Basic copper sulphate, CuSOr.3Cu(OH)zI-Iz Monhydrate copper sulphate, CUSO4.H2O Coarse copper sulphate, CuSO4.5HzO

The following copper carbonates may be substituted for the copper sulphate or any proportions thereof:

Copper carbonate, CuCO3.Cu(OI-I)2 Copper carbonate, 2CuCO3.Cu(OH)2 As previously explained, depending upon the particular application of the cementatory material, the mass of the material may be increased by adding to the dry mixture a quantity of an inert aggregate. organic such as sawdust, cork or Irish peat moss. or inorganic such as sand, sand-gravel, granite chips, Perlite or Fine cones, lava rock pulverized, glass slag, foundry sand, crushed rock, crushed trap rock, diatomaceous earths, kaolin, or talc.

The quantity of aggregate added to the material must, of course, be determined by the particular application. For a water main lining, the cementatory material may be used with a minimum aggregate. For insulation purposes, a quantity of cork'equivalent to eighty times the combined quantities of the remaining ingredients may be used.

The addition of minor proportions of alumina and copper sulphate or copper carbonate to the dry mixture of magnesium oxide and silica has resulted in improved water repellent characteristics as compared to the characteristics of Sorel type cements heretofore known or used. While the exact chemical processes may not be definitely ascertained, one theory of the reason for this phenomenon is that, upon the addition of The aggregate may be either i high tensile strength, compression and impact characteristics. In addition to the new applications available to this improved cement, it may also be used particularly advantageously in building bricks, ship decks, fireplaces, and interior trim.

What is claimed is: 1. A cementatory material having the following percentage composition Mole per cent S102 26-582 MgO 23.3-13.0 A1203 3.0-1.7 CuSO45H2O 1.2-0.7 MgC1z.6H2O 3.62.0 H2O 43.5-24.4

2. A cementatory material having the following percentage composition Mole per cent S102 26-582 MgO 23.3-13.0 A1203 3.0-1.7 CuCO3.Cu(OH) 2 1.2-0.7 MgClaGI-IzO 3.6-2.0 H2O 43.5-24.4

3. A cementatory material comprising an inert aggregate and a binder having the following percentage composition Mole per cent S102 26-582 MgO 23.3-13.0 A1203 3.0-1.7 CLlSO4.5HzO 1.2-0.7

MgClz.6HzO 3.6-2.0 H2O 43.5-24.4

4. A cementatory material comprising an inert aggregate and a binder having the following percentage composition Mole per cent S10 26-582 MgO 23.3-13.0 A1203 3.0-1.7 CuCO3.Cu(OH)z 1.20.7 MgC1z.6H2O 3.6-2.0

5. A cementatory material comprising a magnesium oxy-chloride cement, silica, alumina, and a copper reagent selected from the group consisting of copper sulphate, copper carbonate, and mixtures thereof, the mole percentages of the magnesium oxide of said cement, the alumina, and the copper reagent being, respectively, 23.3 to 13.0, 1.7 to 3.0, and 0.7 to 1.2.

6. A cementatory material according to claim 5 wherein the copper reagent is copper sulphate.

7. A cementatory material according to claim 5 wherein the copper reagent is copper carbonate.

8. A cementatory material including an inert aggregate, in combination with a binder comprisin a magnesium oxy-chloride cement, silica,

alumina, and a copper reagent selected from the group consisting of copper sulphate, copper car- Mole per cent SiOz -1 26-582 MgO 23.8-13.0 A120 3.0-1.7

A copper reagent selected from the group consisting of CuSO4.5H2O,

CuCO3.Cu (OH) 2, and mixtures thereof 1.2-0.7 MgClzfiI-IzO 3.6-2.0 H2O 43.5-24.4

12. A cementatory material including an inert aggregate, in combination with a binder, having 25 the following percentage composition Mole per cent S102 26-582 MgO 23.3-13.0 A1203 3.0-1.7

5 A copper reagent selected from the group consisting of. 01180451520,

CuCO3.Cu(OH) 2; and mixtures thereof 1.2-0.7 MgCl2.6H2O 3.6-2.0 10 H2O 43.5-24.4

EDWARD D. F. WHITEHEAD.

REFERENCES CITED 15 The following references are of record in the file of this'ipatentr...

UNITED :STATES PATENTS Number i Name... I Date 20 2,182,291 Fleuret Dec. 5, 1939 2,351,641 Sohl June 20, 1944 FOREIGN PATENTS Number Country Date 151,589 Germany 1904 

